Fermentation system

ABSTRACT

A precursor base for use in a bakery dough product comprising an acidic concentrate, at least one type of sugar, yeast, at least one type of flour, non-fat dry milk and at least one type of lactic acid producing bacteria and a process for producing the precursor base are disclosed. The precursor base is useful in a process for producing a precursor slurry (or active ferment concentrate) for use in making a preferment dough mixture for the preparation of the bakery dough product. In addition, processes for preparing the precursor slurry and the preferment dough mixture and an apparatus for producing the preferment dough mixture are disclosed.

BACKGROUND OF THE INVENTION

This invention is directed to a new fermentation system that drasticallyreduces the fermentation time and equipment size necessary to producebakery products without corresponding reductions in the quality of thebakery products.

The bakery industry has been faced with the problems of rapidlyincreasing manufacturing costs associated with the steadily rising costsof labor, energy, raw materials, real estate and other such factors. Tocombat these increasing costs, the bakery industry began to look forincreased productivity. The bakery industry, in its yeast-raised productsegment, found that a logical place to decrease manufacturing costs wasin the most time-consuming element, namely the required fermentationtime of the bakery product. Various methods were developed to speed-upfermentation by means of various chemical and physical inducements. Inthe early stages of such developments, the industry found no apparentproblems associated with the reduction of fermentation time. However, asthe trend to cut required fermentation time continued, the industry hascontinued to face increasing new problems, including adverse andundesirable effects on the quality of the bakery products. Bread, rolls,buns and other bakery products started having decreasing amounts offlavor and aroma along with the gradual loss of other such desirablecharacteristics as texture, aesthetic appeal and good shelf life.

One widely accepted method to produce high-quality products is the"sponge and dough", or batch process method which results in thehigh-quality products with good flavor, aroma, desirable texture, andgood shelf life. However, the sponge and dough method is also the mostcostly method due to the requirements of double mixing, approximatelyfour hours fermentation time, and extra handling, all of which requiremuch labor, space, energy, and time. The sponge and dough method is alsointolerant of disruptions in the production process of even shortdurations thus resulting in higher waste if the process is interrupted.

Other methods of production include the flour preferment method, whichnormally contains up to about 50% of the total flour and which producesgood quality products. However, there is some sacrifice of desirableend-product characteristics when compared to the sponge and doughmethod. The flour preferment method, due to the high flour content,requires heavy-duty equipment, large pumps to handle the viscosity ofthe high flour content preferment product, and high energy consumptionfor cooling. In addition, frequent maintenance problems occur in theheat exchange and process flow equipment used in the flour prefermentmethod.

Another production method, the water preferment method, contains noflour, yet offers good yeast distribution. However, the water prefermentmethod requires considerable amounts of water and sugar and producesbelow average quality bakery goods. In addition, such method is verysensitive at the yeast saturation point and therefore requires intensivemonitoring during the preferment process in order to maintain bakeryproduct consistency.

Still another method, the no-time dough method is very simple andrequires no preferment. However, the no-time dough method produces lowerquality goods that sacrifice flavor, aroma and shelf life keepingqualities in exchange for the lower production costs associated with theno-time dough method.

Finally, the continuous mixing method is convenient and cost efficientfor the baking industry. However, the continuous mixing method producesthe least desirable quality bakery products in terms of flavor, aromatexture and keeping qualities.

Previously, it was believed that the function of fermentation was merelyrelated to the gas production in the dough, which would cause the doughto rise and expand. However, extensive investigation into the functionof fermentation has established that several relevant processes occurduring fermentation. Along with the gas production, there is theproduction of chemically identifiable substances such as organic acids,ketones and aldehydes which are end-products of the fermentation processitself. The bakery industry has learned that the only functioneffectively speeded up in a hastened fermentation is the gas production.The other relevant processes and substances have little or no time to beproduced during a fast fermentation system. As such, those processes andsubstances are either missing or undesirably low in such doughs. Thesesubstances have been found to give flavor and aroma to the product andalso cause the various chemical and physical interactions required for agood yeast raised system. Therefore, any compromise in the fermentationsystem will result, in various degrees, in a sacrifice of flavor, aroma,texture and other desirable characteristics. The bakery industry and theflavor companies and other food ingredient companies began developingcompensating materials to replace the sacrificed characteristics, somethrough flavor chemistry, others through enzyme related materials. A fewof these compensating materials have helped to partially overcome theblandness of these fast fermentation bakery products, but none of thecompensating materials has really created or replaced the genuine flavorand other qualities that result from a good fermentation system.Therefore, the current remedies or compensating materials have notoffered much improvement and the baking industry is still addressing thequality deterioration problem associated with shorter fermentationsystems and the resultant dropping per capita consumption of bakeryproducts.

SUMMARY OF THE INVENTION

The present invention provides a technology which offers a significantbreakthrough in solving the problems associated with short fermentation.The present invention greatly improves upon the pre-ferment methodsdescribed above. The present invention provides the necessary elementsthat enable the baker in the bakery industry to produce, through a fastfermentation method, end bakery products that display all of thedesirable characteristics normally achievable only through the longfermentation methods.

The present invention provides, in particular, an active fermentconcentrate comprising yeast, water and a novel precursor base. Theprecursor base comprises an acidic concentrate, at least one type ofsugar, yeast, at least one type of flour, non-fat dry milk, and at leastone type of lactic acid producing bacteria. The precursor base isprepared by combining the acidic concentrate with a portion of the totalsugar to be used in making the precursor base to form a liquidcomposition or slurry. In a separate step the lactic acid producingbacteria is diluted with a small amount of flour. In yet anotherseparate step, the other ingredients, that is, the remaining portions offlour and sugar, the non-fat dry milk, the flour-bacteria dilute and theyeast are combined and thoroughly blended together. During this blendingstep the liquid composition or slurry is added to the combinedingredients. In a preferred embodiment, the ingredients of the precursorbase are present in the following ranges, by weight percent of the totalprecursor base: acidic concentrate 1.2-2.0 wt. percent; sugar 5.0-20.0wt. percent; yeast 0.5-1.5 wt. percent; flour 65.0-85.0 wt. percent;non-fat dry milk 4.0-8.0 wt. percent; and lactic acid producing bacteriaapproximately 5⁵ -15⁵ organisms/grams.

The present invention also provides a practical, efficient universalfermentation system suitable for use in all yeast raised products ofbakery operations. The present invention provides a simplified systemthat can replace any other prefermentation system or combination ofsystems. By changing the proportions of the bakery product ingredients,along with minor procedural changes, the baker can better control theend results to produce bakery products in a wide range of quality. Timerequirements of the present invention are about one-fourth as long ascurrent state-of-the-art systems. The fermentation times required by theflour preferment method are approximately 2 to 21/2 hours. In addition,current state-of-the-art flour preferment systems, which achieve goodbakery product results, require that approximately 50% of the totalflour to be used during the bakery process be added during theprefermenting process. By comparison, the present invention reachesoptimal performance while using approximately 15% of the total flournecessary to produce the bakery product and the fermentation time isapproximately 1/2 hour.

The present invention also provides a simpler and smaller prefermentsystem requiring equipment about seven times smaller than normally usedin the state-of-the-art fermentation systems. The reduction equipment insize and time requirements result in a much smaller fermentation systemwhich produces the same quantity of finished bakery products. Thisresults in significant energy and labor savings. The preferment mixturehandled during the fermentation process of the present invention has arelatively low viscosity, thus requiring equipment which is lighter andsimpler and simpler in design. The present invention eliminates thedouble mixing step required by the sponge method, reduces the containernumber and size requirements present in conventional brewing systemprocesses, and thereby reduces the amount of floor space required. Thepresent invention eliminates the need for multiple transfers of theprefermentation product which is typically required by most conventionalprefermentati systems. In addition, the shorter time and greatertolerances of the preferment mixture of the present invention results asystem requiring smaller holding systems than are required by thecurrent state-of-the-art fermentation systems. The bakery productproduction cycle using the present invention requires no more time thanthe no-time dough methods, yet the quality of bakery goods producedaccording to the method of the present invention is not compromised inany way. Thus, better overall plant utilization is attained.

The present invention further provides increased uniformity,reproducibility, and quality control in the bakery products. Thefermentation system is completely automatic and easily controllable. Thefermentation system is adaptable to microprocessor or microcomputercontrols. After a desired time-temperature relationship has beenestablished in a chosen fermentation system for a particular bakery, thevariation in time to reach the desired pH or yeast saturation point isnominal, and the tolerance to variations in pH or yeast saturation isgreater than the other, known fermentation systems.

The present invention also provides an apparatus which includes aprecursor system containing an agitator means which blends the precursorbase, water and yeast. After multiple incubations in the precursorsystem, a finished precursor slurry or active ferment concentrate isproduced. The precursor slurry is pumped to a fermentor system whichincludes an impeller means which blends the precursor slurry with 15% offlour, water, yeast, yeast nutrients and sugar. The impeller meansthoroughly mixes the precursor slurry, water, flour, yeast, yeastnutrients and sugar to form a preferment mixture. The preferment mixtureis allowed to ferment. When the fermentation cycle has been completedthe preferment mixture can be easily and quickly pumped through a heatexchanger where heat is transferred from the preferment mixture so thatthe preferment mixture achieves the desired temperature. In addition,the preferment mixture can be passed from the heat exchanger into aholding tank system prior to use in preparing the bakery product dough.

The fermentation system of the present invention is simple to use, andwith the use of the active ferment concentrate, the system has unusuallyhigh tolerances and requires little or no monitoring.

Therefore, it is an object of this invention to provide a goodpreferment system which is a vital element in making a good yeast-basedbakery product. The present invention provides a technology whereinconsistent uniform performance is achieved in the production of the endproduct.

The present invention also provides a compact system utilizing onlyapproximately about 15% of the average flour used in a new system. Thepresent invention requires low capital investment, is very energyefficient, and has low maintenance requirements.

Further, it is an object of this invention to provide a prefermentationsystem which is easy to introduce into the commercial bakery and isconvenient to operate.

It is further object of this invention to provide a prefermentationsystem which has high versatility in terms of adjustments to meet thedesired end product and which is of utmost universality for all types ofproduction.

It is a further object of this invention to provide a prefermentationsystem which is extremely economical and which provides savings in costto the finished bakery product.

Other advantages and features of the invention will be apparent from thefollowing description and drawings relating the preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic flowchart of one embodiment of the fermentationsystem of the present invention;

FIG. 2 is a diagrammatic flowchart of an alternative embodiment of thefermentation system of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1, a generalized diagrammatic flowchart is shown,illustrating a fermentation system 10 of the present invention. In thisembodiment, and for the purposes of the following description of thepreferred embodiment, preferment mixtures for yeast raised doughs areprepared.

The fermentation system 10 generally includes a precursor ingrediatorsystem 20 for preparing a precursor slurry (or active fermentconcentrate), a fermentor system 40 for preparing a preferment mixture,optionally, a heat exchanger 60, and, optionally, a holding tank system70. A control station (not shown) is operatively connected to theingrediator system 20, the fermentor system 40, the heat exchanger 60and the holding tank system 70, in a conventional manner and theseconnections are not shown or described in detail. The control station ofthe preferred embodiment includes micro processors which control theoperations of the fermentation system 10.

In the embodiment shown in FIG. 1, the precursor ingrediator system 20generally includes an ingrediator tank 22, and a sweep agitator means24. A portion of the precursor slurry ingredients, namely yeast, a firstportion of the water necessary to form the precursor slurry and a firstportion of the precursor base necessary to form the precursor slurry aremetered or added to the ingrediator tank 22. The precursor base issupplied from a hopper 31 in a conventional manner. The agitator means24 blends the precursor ingredients together to form a first mixture orportion of the precursor slurry. In a preferred process, the firstportion of the precursor slurry comprises approximately one third of therequired water and approximately one third of the required precursorbase. The first portion of the precursor slurry is allowed to incubate.In a preferred process, the first portion of the precursor slurry isallowed to incubate for approximately 40-45 minutes at a preferredtemperature of about 80°-82° F. During this first incubation period, theyeast acts as a catalyst and some fermentation occurs. After the firstincubation period is complete, the first portion of the precursor slurryis relatively viscous and the agitator means 24 blends the first portionof the precursor slurry while adding the next, or second portion of therequired water to the ingrediator tank 22. In a preferred process, thefirst portion of the precursor slurry is blended for approximately 1-2minutes while the water is being added. In a preferred process, thewater is sprayed into the ingrediator tank 22, such that the sprayedwater acts to clean or wash down the side walls of the ingrediator tank22. Thereafter, the next, or second, portion of the precursor base ismetered or added to the incubated first portion of the precursor slurryand is blended by the agitator means 24 to form a second portion of theprecursor slurry, which in a preferred process is blended forapproximately 2-3 minutes. In a preferred process, the second portion ofthe precursor slurry comprises approximately an additional one third ofboth the water and precursor base. The second portion of the precursorbase acts to revitalize the first portion of the precursor slurry. Thesecond portion of the precursor slurry is allowed to incubate. In apreferred process, the second portion of the precursor slurry is allowedto incubate for approximately 40-45 minutes at a preferred temperatureof about 80°-82° F. After the second incubation period is complete, theincubated second portion of the precursor slurry is relatively viscousand the agitator means 24 blends the second portion of the precursorslurry while the last, or third, portion of the water is added to theingrediator tank 22. Again, in a preferred process, the water is sprayedinto the ingrediator tank 22 such that the sprayed water acts to cleanor wash down the side walls of the ingrediator tank 22. In a preferredprocess the second portion of the precursor slurry is blended forapproximately 1-2 minutes while the water is being added. Thereafter,the last, or third, portion of the precursor base is metered or added tothe incubated second portion of the precursor slurry and is blended bythe agitator means 24 to form the third or final portion of theprecursor slurry, which in a preferred process is blended for anotherapproximately 2-3 minutes. In a preferred process, the third portion ofthe precursor slurry comprises approximately an additional one thirdeach of the water and precursor base. The last portion of the precursorbase also acts to revitalize the final portion of the precursor slurry.The final portion of the precursor slurry is then allowed to furtherincubate. In a preferred process, the precursor slurry is allowed toincubate for approximately 40-45 minutes at a preferred temperature ofabout 80°-82° F. After the final incubation period is complete, theresulting precursor slurry, also called the active ferment concentrateherein, has thereby been formed.

The ingrediator system 20 further includes an outlet pipe 26 locatedproximate the bottom of the ingrediator tank 22. The outlet pipe 26penetrates the ingrediator tank 22 and is operatively connected to apneumatic valve 27 and a pump 28 (which are operatively connected to thecontrol station [not shown] in a conventional manner).

After the incubatin period of the precursor slurry is complete,additional water is added and the agitator means 24 blends theadditional water with the precursor slurry. In a preferred process, theadditional water and precursor slurry are blended for approximately 1-2minutes. The pneumatic valve 27 is activated such that the precursorslurry is pumped from the ingrediator tank 22 through the outlet pipe 26by the pump 28 to the fermentor system 30. The fermentor system 30generally includes a fermentor tank 32 with a bottom 33, a top 34, and atemperature sensing means 36. The temperature sensing means 36 isoperatively connected to the control station (not shown). A jacket 35 isplaced around the fermentor tank 32 to control the ambient influence.The fermentor system 30 further includes an impeller means 40 whichrotates and aims a shaft 42. An impeller blade 44 is operativelyattached to the distal end of the shaft 42 such that when the shaft 42is rotated about an axis through the shaft 42, the impeller blade 44 isrotated. Flour is supplied to the fermentor tank 32 from a flour hopper46 in a conventional manner. Water is supplied at a controlledtemperature through piping 39 to the fermentor tank 32. The precursorslurry, (which is also called the active ferment concentrate) flour,water, yeast, yeast nutrients and sugar are blended together by rotationof the impeller means 40 to form a mixture, which in a preferred processare blended for approximately 2 minutes. It will be understood that theterm "yeast" comprises a commercially available inactive yeast and theterm "yeast nutrients" comprises those substances normally employed inthe bakery industry to support the growth and activities of the yeast.The amounts and types of yeast and yeast nutrients correspond to theamounts and types normally employed in the bakery industry. This mixtureis then allowed to ferment. In the preferred fermentation process, themixture is allowed to ferment for approximately 30 minutes at apreferred temperature of about 80°-82° F. to form a completed brew orpreferment mixture. In the preferred embodiment the preferment mixturecontains approximately 15% flour, based on the total flour required bythe final dough product.

The amounts of the various ingredients used in preparing the prefermentslurry can be readily determined by those skilled in the art.

In the embodiment shown in FIG. 1, the fermentor system 30 furtherincludes an outlet pipe 50 located proximate the tank bottom 33. Theoutlet pipe 50 penetrates the bottom 33. The outlet pipe 50 isoperatively connected to a pneumatic valve 51 and a pump 52. Thepneumatic valve 51 and pump 52 are operatively connected to the controlstation (not shown) in a conventional manner. After the prefermentmixture has been blended together with additional water, the pneumaticvalve 51 is activated such that the preferment mixture is pumped fromthe fermentor tank 32 through the outlet pipe 50 by the pump 52. Theoutlet pipe 50 is operatively connected to a three-way valve 53, whichis operatively connected to the control station (not shown). The valve53 directs the flow of the preferment mixture to an inlet pipe 54. Theinlet pipe 54 is operatively connected to the heat exchanger 60 whereheat is transferred from the preferment mixture.

In one embodiment, the preferment mixture is pumped from the fermentorsystem 30 through the heat exchanger 60. The preferment mixture iscooled by the heat exchanger 60 to a desired temperature. In a preferredembodiment the preferment mixture is cooled to a temperature of about40°-45° F. The cooled preferment mixture flows out of the heat exchanger60 through an outlet pipe 61. The outlet pipe 61 is operativelyconnected to a three-way valve 62. The valve 62 directs the cooledpreferment mixture to an inlet pipe 63. The inlet pipe 63 is operativelyconnected to the holding tank system 70.

The holding tank system 70 generally includes a holding tank 72 having abottom 73. A jacket 75 is placed around the holding tank 72 to provideinsulation for the cooled preferment mixture. The holding tank system 70further includes an agitator means 80 to rotate a shaft 82. A slow-sweepagitator 84 is operatively attached to the shaft 82 such that when theshaft 82 is rotated about an axis through the shaft 82, the slow-sweepagitator 84 is rotated. The rotation of the slow-sweep agitator 84 actsto prevent the cooled preferment mixture from separating and preventsthe deposit of sediment on the bottom of the holding tank 72.

The holding tank system 70 further includes a temperature sensor 86 tomonitor the temperature of the cooled preferment mixture. Thetemperature sensor 86 is operatively connected to the control station(not shown) in such a manner that if the temperature of the cooledpreferment mixture rises about a certain predetermined temperature thepreferment mixture is recycled through the heat exchanger 60 until thedesired temperature is reached again.

The holding tank system 70 further includes an outlet pipe 90 locatedproximate the holding tank bottom 73. The outlet pipe 90 penetrates thebottom 73. The outlet pipe 90 is operatively connected to a pneumaticvalve 91 and a pump 92, which are operatively connected to the controlstation (not shown) in a conventional manner. If the preferment mixtureis to be cooled again, the pneumatic valve 91 is activated and thepreferment mixture is pumped from the holding tank 72 through the outletpipe 90 by the pump 92. The preferment mixture is pumped through athree-way valve 93 located at the distal end of the outlet pipe 90. Thethree-way valve 93 is operatively connected to a connecting pipe 95. Theconnecting pipe 95 is operatively connected to the three-way valve 53adjacent the heat exchanger 60. The preferment mixture is forced by thepump 92 through the valve 93, the connecting pipe 95 and the valve 53.The valve 53 is automatically adjusted by the control station (notshown) such that the preferment mixture is pumped through the valve 53through the heat exchanger 60 where the preferment mixture is cooledback to a desired temperature, if it becomes necessary. The three-wayvalve 62 is automatically adjusted by the control station such that thecooled preferment mixture is forced through the holding tank inlet pipe63 back into the holding tank 72. The holding tank system 70 cantherefore operate in a cyclic manner.

At the appropriate time for preparing the dough for the bakery goods,the holding tank pneumatic valve 91 and the pump 92 are activated by thecontrol station (not shown) and the cooled preferment mixture is pumpedfrom the holding tank 72 through the outlet pipe 90. The three-way valve93 is also activated such that the preferment mixture is prevented fromflowing into the connecting pipe 95. The three-way valve 93 is furtherconnected to a supply pipe 97. The three-way valve 93 is activated suchthat the preferment mixture is pumped by the pump 92 from the outletpipe 90 through the three-way valve 93 and into the supply pipe 97. Thesupply pipe 97 can be operatively connected to a flow meter 99. The flowmeter 99 indicates the amount of preferment mixture passing through thesupply pipe 97. The supply pipe 97 is operatively connected to aconventional dough mixer (not shown) such that the preferment mixtureexits the supply pipe 97 into the mixer. The preferment mixture is thenblended with additional flour and other optional ingredients to form thefinal dough product.

The process of the present invention may alternatively proceed asfollows: a first batch or supply of precursor slurry is prepared andincubated in the ingrediator system 20, as described above, and suppliedto the fermentor system 30 as an ingredient for the preferment mixture.The preferment mixture is produced in the fermentor system 30 asdescribed above, cooled by the heat exchanger 60 and held in the holdingtank system 70. While the first batch is being held in the holding tanksystem 70, a second batch of precursor slurry is prepared and incubatedin the ingrediator system 20 and supplied to the fermentor system 30.After the completion of the prefermentation cycle, as described above,the second batch is cooled by the heat exchanger 60. If the first batchbeing held in the holding tank 72 has not been depleted, the secondbatch may be processed through the heat exchanger 60 and supplied to theholding tank 72 on top of the first batch already contained in theholding tank 72. Alternatively, if the holding tank system 70 stillcontains a large quantity of the first produced batch, the secondfermented batch may be cooled by the heat exchanger 60 and passedthrough the three-way valve 62 and through an outlet pipe 65. The secondcooled batch may then be returned to the fermentor tank 32. Thus, thefermentor tank 32 can act as a "holding tank" until the first batchcontained in the holding tank 72 is depleted.

An alternative embodiment of a precursor ingrediator system 120 is shownin FIG. 2 as being attached to the fermentor system 40, heat exchanger60 and holding tank 70, as described above in detail with reference toFIG. 1. The ingrediator system 120 generally includes a firstingrediator tank 122, an agitator means 124 and an outlet pipe 126operatively attached to a pneumatic valve 127 and a pump 128. A portionof the precursor ingredients namely, the yeast, a first portion of thewater and a first portion of the precursor base are metered or added tothe first ingrediator tank 122. The first portion of the precursor baseis supplied from a hopper 131 in a conventional manner. The agitatormeans 124 blends the ingredients together such that a first portion ofthe precursor slurry is formed. The first portion of the precursorslurry is allowed to incubate. In a preferred embodiment, the firstportion of the precursor slurry is allowed to incubate for approximately40-45 minutes at a preferred temperature of about 80°-82° F. During theincubation period, the yeast acts as a catalyst and some fermentationoccurs. After the first incubation period is complete, the first portionof the precursor slurry is relatively viscous and the agitator means 124blends the first portion of the precursor slurry (in a preferred processfor approximately 1-2 minutes), while the next, or second portion of thewater is added to the first ingrediator tank 122. In a preferredembodiment, the water is sprayed into the first ingrediator tank 122such that the sprayed water acts to clean, or wash down, the side wallsof the first ingrediator tank 122. The pneumatic valve 127 is activatedand the first portion of the precursor slurry is pumped from the firstingrediator tank 122 through the outlet pipe 126 by the pump 128 to asecond ingrediator tank 132.

The second ingrediator tank 132 is operatively connected to an agitatormeans 134, an outlet pipe 136, a pneumatic valve 137 and a pump 138. Thenext, or second, portion of the precursor base is metered or added fromthe hopper 131 to the first portion of the precursor slurry in thesecond ingrediator tank 132 are blended by the agitator means 134 (in apreferred process for approximately 2-3 minutes). The second portion ofthe precursor base acts to revitalize the first portion of the precursorslurry. The second portion of the precursor slurry is allowed toincubate. In a preferred process, the second portion of the precursorslurry is allowed to incubate for approximately 40-45 minutes at apreferred temperature of about 80°-82° F. After the second incubationperiod is complete, the second portion of the precursor slurry is againrelatively viscous and the agitator means 134 blends the second portionof the precursor slurry (in a preferred process for approximately 2-3minutes), while the last or third portion of the water is added to thesecond ingrediator tank 132. Again, in a preferred embodiment, the wateris sprayed into the second ingrediator tank 132 such that the sprayedwater acts to clean or wash down the side walls of the ingrediator tank132. The pneumatic valve 137 is activated and the second portion of theprecursor slurry is pumped from the second ingrediator tank 132 throughthe outlet pipe 136 by the pump 138 to a third ingrediator tank 142.

The third ingrediator tank 142 is operatively connected to an agitatormeans 144, an outlet pipe 146, a pneumatic valve 147 and a pump 148.Thereafter the last or third, portion of the precursor base is meteredfrom the hopper 131 to the precursor slurry in the third ingrediatortank 142. The precursor slurry and the last portion of the precursorbase are blended by the agitator means 144 (in a preferred process forapproximately 2-3 minutes). The last portion of the precursor base alsoacts to revitalize the resulting precursor slurry or active fermentconcentrate. The precursor slurry is then allowed to further incubate.In a preferred process, the precursor slurry is allowed to incubate forapproximately 40-45 minutes at a preferred temperature of about 80°-82°F. After incubation in the third ingrediator tank 142 is complete,additional water is added to the third ingrediator tank 142. Again, in apreferred embodiment, water is sprayed into the ingrediator tank 142such that the sprayed water acts to clean or wash down the side walls ofthe ingrediator tank 142. Thus, the precursor slurry, upon being pumpedfrom the ingrediator tank 142 into the fermentor system 30, has arelatively low viscosity. Thereafter, the pneumatic valve 147 isactivated and the precursor slurry is pumped from the third ingrediatortank 142 through the outlet pipe 146 by a pump 148 to the fermentorsystem 30. According to the present invention once the fermentationprocess has been started, the tanks 122, 132 and 142 can be filled everyhour and the precursor base can be dispensed from the hopper 131 intoall three tanks at about the same time.

In a preferred embodiment the ingrediator tank 22, as shown in FIG. 1,is a relatively tall and narrow tank in order to accommodate theseparate portions of the precursor slurry being incubated therein. Inanother preferred embodiment the agitator tanks 122, 132 and 142, asshown in FIG. 2, vary in dimensions. Size requirements varies with givenproduction requirements.

The precursor slurry or active ferment concentrate disclosed herein isespecially useful with the above-described fermentation method andapparatus. The active ferment concentrate provides the necessary qualityfactors for producing a quality end-product. These factors includeeating qualities such as flavor, aroma and crumb structure along withthe overall appearance qualities of volume symmetry, interior andexterior colors of the product, texture and desired softness and theshelf life qualities. It is necessary that the active fermentconcentrate produce the desired pH in the end-product.

The active ferment concentrate, as discussed above, comprisespredetermined quantities of yeast, water and precursor base. Theprecursor base comprises the following ingredients: an acidicconcentrate, at least one type of sugar, yeast, at least one type offlour, non-fat dry milk, and at least one type of lactic acid producingbacteria. The ingredients in the precursor base all contribute to thedesirable properties of the bakery end-products. In a preferredembodiment, the pH range of the precursor base ranges from about 4.5-5.5and is most preferably within the range of about 4.9-5.1.

The acidic concentrate provides a supply of ascorbic acid and flavoringand acts as a natural oxidant. In a most preferred embodiment, theacidic concentrate comprises a lemon concentrate which comprises about60% solids, by weight, and about 40%, by weight, water. The lemonconcentrate is commercially available as a frozen product.

The sugar provides substrates and contributes to the general flavordevelopment of the end-product. Sugars which are especially useful inmaking the precursor base include malt syrup, molasses, sucrose anddextrose. In a preferred embodiment a desired balance is achievedbetween the amounts of molasses, malt syrup, sucrose and dextrose inorder to achieve proper carmelization, or colorization, of the bakeryend-product.

The yeast is a good contributor of protein and has desirable flavorcharacteristics. The yeast metabolizes with the other ingredients in theactive ferment concentrate and also provides desirable flavorcharacteristics to the end-product. In a preferred embodiment the yeastcomprises a commercially available inactive dry yeast.

The flour acts as a carrier and a support to the precursor base and tothe and dough product. In a preferred embodiment more than one type offlour is used in preparing the precursor base. For example, it ispreferred that one of the flours comprise wheat flour and the otherflour comprise rye flour. In a preferred embodiment, when the rye flouris used in the precursor base the rye flour potentiates the flavor andaroma characteristics of the bakery end-product and influences some ofthe acid developments which occur during the incubation and fermentationstages. It is also preferred that other, smaller quantities of flour,such as soya flour and potato flour constitute a portion of the totalflour used in the precursor base. The soya flour is a good source ofprotein. The potato flour also acts as a starch and a stabilizingmaterial. The potato flour acts as a humectant, that is an anticakingmaterial, which absorbs excess moisture from the precursor base.Further, the addition of potato flour aids in prolonging the shelf-lifeof the bakery end-product. It should be noted that while theconcentration of rye flour to wheat flour in the precursor base may berelatively high in proportion to the remaining ingredients in the activeferment concentrate, the rye flour is present in negligible quantitiesin the final bread product.

The non-fat dry milk provides mineral and protein content to theprecursor base. The milk, along with the lactic acid producing bacteria,becomes active by producing lactic acid during the preparation of theactive ferment concentrate, as will be explained in detail below, andduring the incubation stages of the precursor slurry.

The lactic acid producing bacteria, along with the non-fat dry milk,produces lactic acid. Any lactic acid producing bacteria can be utilizedin the present invention including for example, lactobacillusacidophilus, l. brevis, l. buchneri, l. bulgaricus, l. casei, l.delbrueckii, l. fermenti, l. lactis, l. leichmannii, l. pastoriamus, l.pentoaceticus, l. thermophilus, streptococcus citrovorus, and s. lactis,or a mixture thereof. A preferred bacteria comprises lactobacillusacidophilus.

In the preparation of the precursor base for the active fermentconcentrate, a liquid composition or slurry is formed by combining theacidic concentrate with a portion of the total sugar to be used inmaking the precursor base. In a preferred embodiment, the liquid slurryhas a temperature in the range of about 60°-65° F. and has sufficientliquidity without becoming warm.

In a separate step, the lactic acid producing bacteria, which iscommercially available as a freeze dried product, is diluted with asmall amount of flour. The dilution is preferably made to about 10⁸organisms per gram.

In another separate step the other ingredients, namely the remainingportions of sugar and flour, the non-fat dry milk, the flour-bacteriadilute and the yeast are combined and thoroughly blended together.During this blending step, the liquid slurry is added to the combinedingredients. In a preferred embodiment the liquid slurry is sprayed intothe combined ingredients being blended together.

If necessary, in order to rid the precursor base of any lumps, theprecursor base may be run through a multiple sifting device or through amill. It is desirable that any lumps be broken apart since the lumpspresent are mostly comprised of sugar and acidic concentrate and suchlumps lead to deterioration and shorten the shelf life of the precursorbase. When the precursor base is well blended and relatively small or nolumps are present, the precursor base is extremely stable. In addition,when the precursor base is utilized for producing the active fermentconcentrate (or precursor slurry), as described above, the desiredproportions of normal fermentation by-products are developed, thusproducing high quality end-products. Thus, the precursor baseconstitutes approximately 1.0-1.5 percent, by weight, based on the totalflour in the dough. The active ferment concentrate (or precursor slurry)constitutes about 2-3 percent, by weight, of the total flour in thedough. The precursor base can be stored in the same manner as flour inbags is typically stored and has a shelf life of at least 6 months.

In a preferred embodiment the precursor base comprises the followingingredients in the following approximate ranges, by weight percent, ofthe total precursor base:

    ______________________________________                                        acidic concentrate                                                                       1.2-2.0 wt. %                                                      sugar      5.0-20.0 wt. %                                                     yeast      0.5-1.5 wt. %                                                      flour      65.0-85.0 wt. %                                                    non-fat dry milk                                                                         4.0-8.0 wt. %                                                      lactic bacteria                                                                          approximately 5.sup.5 × 15.sup.5 organisms/grams             ______________________________________                                    

In an especially preferred embodiment the precursor base ingredients arepresent in the following weight percentages:

    ______________________________________                                        acidic concentrate                                                                          1.6 wt. %                                                       sugar         13.3 wt. %                                                      yeast         1.0 wt. %                                                       flour         78.1 wt. %                                                      non-fat dry milk                                                                            6.0 wt. %                                                       lactic bacteria                                                                             approximately 10.sup.5 organisms/grams                          ______________________________________                                    

In a preferred process for preparing the precursor base, the acidicconcentrate is blended together with about 15%, by weight of the totalamount of the sugar present in the precursor base in order to form theliquid slurry. In a preferred embodiment, the amount of sugar in theliquid slurry comprises about 1-3%, by weight, and most preferably about2.0%, by weight, of the precursor base. In a most preferred embodiment,the sugar in the liquid slurry comprises malt syrup.

The sugar ingredients in a preferred embodiment comprise about 1-3%, byweight, malt syrup and most preferably about 2%, by weight; about 1-2%,by weight, molasses and most preferably about 1.8%, by weight, whereinthe molasses if in liquid form can be sprayed onto the remainingingredients or if in dry form added with the other sugars; about5.0-10.0%, by weight, sucrose and most preferably about 7.5%, by weight;and, about 0-4.0%, by weight, dextrose, and most preferably about 2.0%,by weight.

The flour ingredients in a preferred embodiment comprise about 35-45%,by weight, wheat flour and most preferably about 42.5%, by weight; about25-35%, by weight, rye flour and most preferably about 30.0%, by weight;about 2.5-3.0%, by weight, potato flour and most preferably about 2.8%,by weight; and, about 2.5-3.0%, by weight, soya flour and preferablyabout 2.8%, by weight.

In an alternative embodiment of producing the precursor base, if nosprayer is available, the liquid slurry comprising the acidicconcentrate and a first portion of the sugar (in a preferred embodiment,the malt syrup) are blended together to form the liquid slurry andthereafter the remaining portion of sugar is blended together with theliquid slurry. Thereafter, the yeast and first portion of the flour (ina preferred embodiment, the soya flour) is gradually mixed in untilblended. Thereafter, a second portion of the flour (in a preferredembodiment the second portion comprises rye and wheat flour) aregradually mixed in until blended. Thereafter, a third portion of flour(in a most preferred embodiment, the potato flour) is gradually mixed inuntil blended. Thereafter, the non-fat dry milk and the lactic acidproducing bacteria diluted with a fourth portion of the flour aregradually mixed until blended together to form the precursor base.

The above detailed description of the present invention is given forexplanatory purposes. It will be apparent to those skilled in the artthat numerous other changes and modifications can be made in thepreferred embodiments of the invention described above without departingfrom the scope of the invention. Accordingly, the whole of the foregoingdescription is to be construed in an illustrative and not a limitativesense, the scope of the invention being defined solely by the appendedclaims.

I claim:
 1. A precursor base for an active ferment concentrate whereinsaid precursor base consists essentially of by weight percent, based onthe total weight of the precursor base, approximately:

    ______________________________________                                        acidic concentrate                                                                               1.2-2.0 wt. %;                                             sugar              5.0-20.0 wt. %;                                            inactive yeast     0.5-1.5 wt. %;                                             flour             65.0-85.0 wt. %;                                            non-fat dry milk   4.0-8.0 wt. %; and                                         lactic bacteria   approximately 5.sup.5 to 15.sup.5                                             organisms/gram.                                             ______________________________________                                    


2. The precursor base for an active ferment concentrate of claim 1wherein the precursor base consists essentially of by weight percent,based on the total weight of the precursor base, approximately:

    ______________________________________                                        acidic concentrate                                                                           1.6 wt. %;                                                     sugar          13.3 wt. %;                                                    inactive yeast 1.0 wt. %;                                                     [first portion] flour                                                                        78.1 wt. %;                                                    non-fat dry milk                                                                             6.0 wt. %;    and                                              lactic bacteria                                                                              approximately 10.sup.5 organisms/gram.                         ______________________________________                                    


3. An active ferment concentrate comprising:(1) a precursor baseconsisting essentially of an acidic concentrate, at least one type ofsugar, inactive yeast, at least one type of flour, non-fat dry milk, andat least one type of lactic acid producing bacteria by weight percent,based on the total weight of the precursor base, approximately:

    ______________________________________                                        acidic concentrate                                                                               1.2-2.0 wt. %;                                             sugar              5.0-20.0 wt. %;                                            inactive yeast     0.5-1.5 wt. %;                                             flour             65.0-85.0 wt. %;                                            non-fat dry milk   4.0-8.0 wt. %; and                                         lactic bacteria   approximately 5.sup.5 to 15.sup.5                                             organisms/gram;                                             ______________________________________                                    

(2) catalytic-acting yeast, and (3) water.
 4. The active fermentconcentrate of claim 3 comprising approximately 50% water andapproximately 2% catalytic-acting yeast, by weight, based on the totalweight of the active ferment concentrate.
 5. The precursor base for anactive ferment concentrate of claim 3, wherein the acidic concentratecomprises a lemon concentrate.
 6. The precursor base for an activeferment concentrate of claim 5 wherein the lemon concentrate comprisesabout 60% total solids therein.
 7. The precursor base for an activeferment concentrate of claim 3, wherein the sugar is selected from thegroup comrising malt syrup, molasses, sucrose and dextrose, or a mixturethereof.
 8. The precursor base for an active ferment concentrate ofclaim 3, wherein the sugar comprises, by weight percent based on thetotal weight of the precursor base, about 1-3 wt. % malt syrup, 1-2 wt.% molasses, 5-10 wt. % sucrose and about 0-4 wt. % dextrose.
 9. Theprecursor base for an active ferment concentrate of claim 3, wherein thesugar comprises by weight percent about: 2 wt. % malt syrup; 1.8 wt. %molasses; 7.5 wt. % sucrose; and, 2.0 wt. % dextrose.
 10. The precursorbase for an active ferment concentrate of claim 3, wherein the flour isselected from the group comprising wheat flour, rye flour, soya flourand potato flour, or a mixture thereof.
 11. The precursor base for anactive ferment concentrate of claim 3, wherein the flour comprises, byweight percent based on the total weight of the precursor base, about:35-45 wt. % wheat flour; 25-35 wt. % rye flour; 2.5-3 wt. % potatoflour; and 2.5-3 wt. % soya flour.
 12. The precursor base for an activeferment concentrate of claim 3, wherein the flour comprises by weightpercent about 42.5 wt. % wheat flour; 30.0 wt. % rye flour; 2.8 wt. %potato flour, and 2.8 wt. % soya flour.
 13. The precursor base for anactive ferment concentrate of claim 3, wherein the lactic acid producingbacteria is selected from the group including: lactobacillusacidophilus, l. brevis, l. buchneri, l. bulgaricus, l. casei, l.delbrueckii, l. fermenti, l. lactis, l. leichmannii, l. pastoriamus, l.pentoaceticus, l. thermophilus, streptococcus citrovorus, and s. lactis,or a mixture thereof.
 14. The precursor base for an active fermentconcentrate of claim 3, wherein the lactic acid producing bacteriacomprises lactobacillus acidophilus.
 15. The active ferment concentrateof claim 3 wherein the precursor base consists essentially of by weightpercent, based on the total weight of the precursor base, approximately:

    ______________________________________                                        acidic concentrate                                                                          1.6 wt. %;                                                      sugar         13.3 wt. %;                                                     inactive yeast                                                                              1.0 wt. %;                                                      flour         78.1 wt. %;                                                     non-fat dry milk                                                                            6.0 wt. %;    and                                               lactic bacteria                                                                             approximately 10.sup.5 organisms/gram.                          ______________________________________                                    


16. The active ferment concentrate of claim 3, wherein the acidicconcentrate comprises a lemon concentrate.
 17. The active fermentconcentrate of claim 16 wherein the lemon concentrate comprises about60% total solids therein.
 18. The active ferment concentrate of claim 3,wherein the sugar is selected from the group comprising malt, syrup,molasses, sucrose and dextrose, or a mixture thereof.
 19. The activeferment concentrate of claim 3, wherein the sugar comprises, by weightpercent based on the total weight of the precursor base, about 1-3 wt. %malt syrup, 1-2 wt. % molasses, 5-10 wt. % sucrose and about 0-4 wt. %dextrose.
 20. The active ferment concentrate of claim 3, wherein thesugar comprises, by weight percent based on the total weight of theprecursor base, about 2 wt. % malt syrup, 1.8 wt. % molasses, 7.5 wt. %sucrose and about 2 wt. % dextrose.
 21. The active ferment concentrateof claim 3, wherein the flour is selected from the group comprisingwheat flour, rye flour, soya flour and potato flour, or a mixturethereof.
 22. The active ferment concentrate of claim 3, wherein theflour comprises, by weight percent based on the total weight of theprecursor base, about: 35-45 wt. % wheat flour; 25-35 wt. % rye flour;2.5-3 wt. % potato flour; and 2.5-3 wt % soya flour.
 23. The activeferment concentrate of claim 3, wherein the flour comprises by weightpercent about 42.5 wt. % wheat flour; 30.0 wt % rye flour; 2.8 wt. %potato flour, and 2.8 wt. % soya flour.
 24. The active fermentconcentrate of claim 3, wherein the lactic acid producing bacteria isselected from the group including: lactobacillus acidophilus, l .brevis, l. buchneri, l. bulgaricus, l. casei, l. delbrueckii, l.fermenti, l. lactis, l. leichmannii, l. pastoriamus, l. pentoaceticus,l. thermophilus, streptoccoccus citrovorus, and s. lactis, or a mixturethereof.
 25. The active ferment concentrate of claim 3, wherein thelactic acid producing bacteria comprises lactobacillus acidophilus.